Portable profiler for locomotive or railcar wheels

ABSTRACT

A portable apparatus for configuring a wheel associated with a track is provided. The apparatus is in a fixed position with respect to a rail associated with the track when in operation. The apparatus includes a tool configured to engage the wheel, a position system for positioning the cutting tool in at least two axis, and a computer control. The computer control is coupled to control the positioning system. The positioning system is controlled so that the wheel is configured in accordance with a profile.

CROSS-REFERENCE TO RELATED APPLICATION

The present application claims priority to and is a continuation of U.S.application Ser. No. 16/273,936 entitled “PORTABLE PROFILER FORLOCOMOTIVE OR RAIL CAR WHEELS” filed on Feb. 12, 2019 which is acontinuation-in-part of U.S. application Ser. No. 13/745,520, entitled“PORTABLE PROFILER FOR LOCOMOTIVE OR RAIL CAR WHEELS” filed on Jan. 18,2013, which is a continuation-in-part of U.S. application Ser. No.13/428,952 (n/k/a U.S. Pat. No. 8,408,105), entitled “PORTABLE PROFILERFOR LOCOMOTIVE OR RAILCAR WHEELS”, filed on Mar. 23, 2012, which is acontinuation of U.S. application Ser. No. 12/171,151 (n/k/a U.S. Pat.No. 8,186,250), entitled “WHEEL LATHE FOR RAILROAD CARS ANDLOCOMOTIVES”, filed on Jul. 10, 2008, all of which are incorporatedherein by reference in their entireties. U.S. application Ser. No.13/745,520 is a continuation-in-part of PCT/US2012/036755 which claimspriority to provisional Application No. 61/484,562, filed on May 10,2011; U.S. application Ser. No. 13/745,520 is a continuation-in-part ofU.S. application Ser. No. 13/587,740 (n/k/a U.S. Pat. No. 9,358,650),filed Aug. 16, 2012, which claims priority to provisional ApplicationNo. 61/524,652, filed on Aug. 17, 2011; and U.S. application Ser. No.13/745,420 is a continuation-in-part of U.S. application Ser. No.12/886,418, (n/k/a U.S. Pat. No. 8,789,448), all of which are hereinincorporated by reference in their entireties.

FIELD

The present disclosure relates generally to the field of maintenance forrailway vehicles. More specifically, the present disclosure relates toan apparatus for machining and maintaining the wheels of a locomotive orrailway car.

BACKGROUND OF THE INVENTION

Wheels on railway locomotives and cars are subject to abuse and wear inthe course of normal use. This wear changes the contour of the wheel,forming undesirable contours including flats, high flanges and othercontours that adversely affect the performance of the wheel. A wornwheel can reduce ride quality, increase the risk of derailments, andcontribute to increased wear, fatigue, noise, and excessive fuelconsumption.

Locomotive and railcar wheel maintenance is important to safety andefficient operation of railways. Locomotive and railcar wheelmaintenance typically involves removing the locomotive or railcar fromservice and re-profiling or “retruing” the wheel with a lathe mechanism.Such known lathe mechanisms may be provided in pits below removable railsections. Such mechanisms may be computer numerical control (CNC)machines and are generally large, expensive, and not portable.Stationary mechanisms require establishing a permanent maintenancefacility or area and removing the locomotive or railcar from service.

Locomotive and railcar wheels may also be re-profiled with manual lathemechanisms. However, such manual processes are generally time-consumingand require intense labor, taking as many as 8 hours to re-profile apair of wheels. In addition, some known processes create a long,continuous chip. A machinist is required to wear safety gear such asheavy leather clothing and a face shield to avoid being injured by theextremely hot, razor sharp chips.

Thus, there is a need for a portable re-profiling system for wheels oflocomotives or railcars. Furthermore, there is a need for a lathemechanism that is more efficient and safer than manual lathe mechanisms.Further still, there is a need for an automated re-profiling system thatis quick, efficient and less expensive than conventional systems locatedin permanent maintenance facilities.

SUMMARY OF THE INVENTION

An exemplary embodiment relates to a portable apparatus for configuringa wheel associated with a track. The apparatus is in a fixed positionwith respect to a rail associated with the track when in operation. Theapparatus includes a tool configured to engage the wheel, a positioningsystem for positioning the cutting tool in at least two axes, and acomputer control. The computer control is coupled to control thepositioning system. The positioning system is controlled so that thewheel is configured in accordance with a profile.

Another exemplary embodiment relates to a portable cutting system forprofiling a wheel while attached to a rail car or locomotive on a track.The system includes means for attaching the cutting system to the track.The system also includes means for profiling the wheel in accordancewith a stored profile in the portable cutting system.

Another exemplary embodiment relates to a portable system for profilingthe wheel in accordance with an electronically stored profile. The wheelis associated with a train in the field. The system includes a cuttingtool configured to engage the wheel, a positioning system forpositioning the cutting tool, and a control for controlling thepositioning system. The positioning system is controlled so that thewheel is shaped in accordance with the profile.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is an isometric view of a railroad car according to an exemplaryembodiment.

FIG. 2 is a block diagram of an apparatus for re-profiling a wheel for arailroad car of FIG. 1 according to an exemplary embodiment.

FIGS. 3A and 3B are isometric views of an apparatus for re-profiling awheel for a railroad car of FIG. 1 according to an exemplary embodiment.

FIG. 4 is top view of the apparatus of FIG. 2 for re-profiling a wheelfor a railroad car.

FIG. 5 is a bottom isometric view of the apparatus of FIG. 2 , showing amechanism for coupling the apparatus to a rail.

FIGS. 6-7 are isometric views of a drive mechanism for the apparatus ofFIG. 2 according to one exemplary embodiment.

FIG. 8 is an isometric view of a cutting tool for the apparatus of FIG.2 according to an exemplary embodiment.

FIGS. 9A-9B are top views of two exemplary wheel profiles for a wheelfor the railcar of FIG. 1 .

FIG. 10 is a flowchart of a method for profiling a wheel according to anexemplary embodiment.

FIG. 11 is a top view of an apparatus for re-profiling a wheel for arailroad car according to another exemplary embodiment.

FIG. 12 is a front view of a drive mechanism for an apparatus forre-profiling a wheel for a locomotive according to an exemplaryembodiment.

FIGS. 13 and 14 are isometric views of a drive mechanism for anapparatus for re-profiling a wheel for a railroad car according toanother exemplary embodiment.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

Referring in general to the FIGURES and more specifically to FIGS. 2-4 ,an apparatus 20 for profiling or re-profiling the wheels 12 of a railcar10 is shown according to an exemplary embodiment. For the purpose ofthis specification and the claims, railroad cars include any wheeledsystems configured for riding on railroad tracks or rails, including,for example, a locomotive 11 and a railcar 10 shown in FIG. 1 .Apparatus 20 is a computer controlled lathe apparatus that is configuredto be coupled to tracks 18 upon which locomotive 11 or railcar 10 rides.

Apparatus 20 is a portable lathe device that is configured to be coupledto the track or rail 18 upon which wheels 12 of a railcar 10 areresting. To provide a precise profile for wheel 12 with a relativelyshort cycle time, apparatus 20 is a computer numerical control (CNC)lathe. The desired profile 82 for wheel 12 and the cutting path neededto provide the profile for wheel 12 is stored in a computer control 80coupled to apparatus 20. Apparatus 20 includes a cutting tool 24 with aninsert 26. A profile for wheel 12 is provided by rotating wheel 12 andmoving cutting tool 24 relative to wheel 12 with a 2-axis slidemechanism 30. A user may operate an interface 84 coupled to computercontroller 80 to control apparatus 20.

Apparatus 20 is able to be easily moved to a railcar 10 or locomotive 11anywhere instead of having to move the railcar 10 or locomotive 11 toapparatus 20. While most existing mechanisms can weigh in access ofseveral tons, apparatus 20 weighs approximately 450 lbs. Apparatus 20,for example, may be used to service a railcar 10 or locomotive 11 thatis broken down at a location away from a station or service area.According to one exemplary embodiment, apparatus 20 wheels may becoupled to apparatus 20. According to another exemplary embodiment,apparatus 20 may be transported by a vehicle such as a forklift.

As shown best in FIG. 5 , apparatus 20 is coupled to rail 18 with amounting mechanism 90. Mounting mechanism 90 rides on the top of a rail18 aligned with a wheel 12 to be machined. Mounting mechanism 90 isconfigured to support apparatus 20 such that apparatus is level, firmlycoupled to rail 18, and rotated to be aligned with wheel 12. Accordingto an exemplary embodiment, mounting mechanism 90 includes a plate ormain body 92, one or more clamps 96, a location bar 100, and a push bar108.

Location bar 100 is placed along the edge of rail 18 to locate apparatus20 above rail 18 (e.g., so that the apparatus 20 is approximatelyaligned with rail 18). Wheels 12 and axle 14 may be configured to rotateslightly about a vertical axis (e.g., to facilitate railcar 10, 11moving along curved rails). When railcar 10, 11 is elevated from rails18, wheels 12 and axle may rotate about this horizontal axis. Themagnitude and direction of this rotation is generally unpredictable. Tocompensate for the rotation and to align apparatus 20 with wheel 12,location bar 100 is coupled to plate 92 with a pinned connection (notshown) provided generally in the middle of location bar 100. Locationbar 100 includes one or more holes 102, that are aligned withcorresponding slots 104 (FIG. 4 ) in plate 92. Once apparatus 20 isrotated so it is aligned with wheel 12, fasteners passing through holes102 are tightened to prevent apparatus 20 from rotating about the pinnedconnection of location bar 100.

Clamps 96 are movable in a direction generally perpendicular to rail 18.Clamps 96 are coupled to plate 92 by a fastener that passes through ahole 98 in clamp 96 and a corresponding slot 94 in plate 92. Accordingto one exemplary embodiment, clamps 96 are coupled to plate 92 with abolt that engages a nut. As the bolt is tightened, the head of the boltand the nut compress clamp 96 against plate 92, preventing clamp 96 frommoving relative to plate 92. When apparatus 20 is placed on rail 18,clamps 96 are moved to compress rail 18. A push rod 108 (FIG. 12 ) isprovided to limit the movement of apparatus 20 perpendicular to rail 18.One end of push rod 108 is coupled to apparatus while the opposite endextends to contact the opposite rail 18 (e.g. the rail apparatus 20 isnot resting on) or another suitable stationary object.

According to one exemplary embodiment, apparatus 20 is leveled (e.g., socutting tool 24 moves along a horizontal plane). A multitude of threadedholes 106 are provided about the periphery of plate 92. Holes 106receive leveling mechanisms such as threaded rods (not shown) with anend that contacts the ground. By turning the leveling mechanisms, theymove in a vertical direction relative to plate 92 and move variousportions of plate 92 and, in turn, apparatus 20, up or down. Accordingto one exemplary embodiment, holes 106 are provided at each corner ofplate 92. According to other exemplary embodiments, holes 106 may beprovided elsewhere (e.g., along a side of plate 92).

As shown best in FIG. 8 , cutting tool 24 includes an insert 26 that issecured with an insert clamp 28 (e.g., retainer, holder, etc.). Theedges of wheels 12 being profiled may include imbedded sand, stones, andother foreign debris. Cutting tool 24 includes a high-quality cuttingtool insert 26 that is able to withstand the wear from the imbeddedparticles. According to one exemplary embodiment, insert 26 is formedfrom a tungsten carbide material. According to other exemplaryembodiments, insert 26 may be formed from cermet, a coated carbide, aceramic material, or any other suitable material known in the art. Whileinsert 26 is shown as a generally cylindrical member in FIGS. 3 and 8 ,according to other exemplary embodiments it may have a wide variety ofgeometries.

Wheel 12 is turned so cutting tool 24 can profile the entirecircumference of wheel 12 with a drive mechanism 50. Drive mechanism 50includes a base 51, power source such as drive motor 52, a gear reducer54, and a sprocket 56 coupled to a wheel 12 opposite of the wheel 12 tobe profiled (e.g. on the same axle 14). Sprocket 56 is bolted orotherwise coupled to the end of wheel 12 opposite of wheel 12 to beprofiled. Because both wheels 12 are mounted on the same solid axle 14,turning one wheel also turns the other. Gear reducer 54 is providedbetween drive motor 52 and sprocket 56 to reduce the rotational speed towheel 12 and increase the torque to wheel 12. The output shaft of gearreducer 54 is coupled to sprocket 56 with a chain 58. According to otherexemplary embodiments, wheel could be driven by other means (e.g., amotor coupled directly to the wheel, with a roller contacting the edgeof the wheel, etc.). According to an exemplary embodiment, wheel 12 isturned at approximately 30-40 revolutions per minute. According to otherexemplary embodiments, wheel 12 may be turned a another rate dependingon a variety of factors, including the cutting tool material, cuttingtool geometry, motor speed, etc. According to one exemplary embodiment,drive motor 52 is a 15 hp AC motor and gear reducer 54 provides a gearreduction ration of 40:1.

Referring to FIGS. 13 and 14 , according to another exemplaryembodiment, a drive mechanism 150 uses a friction wheel to turn wheel 12and axle 14. Drive mechanism 150 is similar to drive mechanism 50, butincludes a drive motor 152 that turns a friction wheel such as a roller157. Roller 157 is compressed against a wheel 12 opposite of the wheel12 to be profiled (e.g. on the same axle 14). A gear reducer may beprovided between drive motor 152 and roller 157. Roller 157 is rotatedby motor 152 and, in turn, rotates wheels 12 and axle 14.

Cutting tool 24 is coupled to a slide mechanism 30 that allows cuttingtool 24 to be movable relative to wheel 12 along both an x-axis 40 and ay-axis 42. Slide mechanism includes a first slide 31 that moves alongx-axis 40, parallel to axle 14, and a second slide 35 that moves alongy-axis 42, perpendicular to axle 14. A first power source 32 is providedto move first slide 31. A second power source 36 is provided to movesecond slide 35. As described above, according to one exemplaryembodiment, apparatus 20 is a CNC lathe, and power sources 32 and 36 areelectric motors (e.g., servo motors, stepper motors, etc.) that arecontrolled with signals from a computer controller. Power sources 32 and36 are coupled to gear reducers 33 and 37, respectively. Gear reducers33 and 37 reduce the shaft speed and increase the torque from powersources 32 and 36. According to various exemplary embodiments, gearreducers 33 and 37 may be directly coupled to the slide mechanism or maybe coupled to the slide mechanism through a transfer mechanism.

As shown according to one exemplary embodiment in FIG. 3 , power source32 and gear reducer 33 are coupled directly to the threaded drive shaft110 for first slide 31 while power source 36 and gear reducer 37 arecoupled to the threaded drive shaft 112 of second slide 35 throughtransfer mechanism 38. Transfer mechanism 38 may be any mechanism thatsuitably transfers rotational power, such as a belt and pulleymechanism, a chain and sprocket mechanism, or a gear set. According toan exemplary embodiment, transfer mechanism 38 includes a timing belt(not shown) that engages two pulleys. Transfer mechanisms may beprovided to reposition power sources (e.g., to provide a more compactapparatus 20), and/or, to further lower or raise the rotational speed ofthe drive shafts for slide mechanism 30 (e.g., by providing twodifferently sized pulleys or sprockets or a reducing gear set). A guardor casing (not shown) may be provided to prevent inadvertent contactbetween a person or object and the moving components of transfermechanism 38. According to one exemplary embodiment, power sources 32and 36 are servo motors and gear reducers 33 and 37 are 20:1 gearreducers. According to other exemplary embodiments, power source 32 and36 may be a hand wheel with tracer system.

Second slide 35 may be configured to rotate about a vertical axisrelative to base 22 and mounting mechanism 90. According to an exemplaryembodiment, second slide 35 can be locked at two positions 180 degreesapart to service both wheels 12 on axle 14 while engaging the insideedge of either rail 18 by reorienting mounting mechanism 90 relative tosecond slide 35.

As cutting tool 24 profiles wheel 12, it may form a chip of removedmaterial. Because apparatus 20 profiles wheel 12 with an automated CNCprocess, a user does not need to be in close proximity to wheel 12 as itis being machines, reducing the chance of the user being cut by thechip.

Referring now to FIG. 10 , a method for profiling wheels 12 on a railcar10 or locomotive 11 involve first disengaging wheels 12 from rails 18(step 70). According to an exemplary embodiment, a jack or lift 19 (FIG.12 ) is used to raise one set of wheels 12 off of rails 18 while leavingthe other set of wheels engaged. Wheels 12 and axle 14 are both leftcoupled to railcar 10 or locomotive 11 to reduce the amount of timeneeded to profile wheels 12.

After wheels 12 have been disengaged from rails 18, apparatus 20 iscoupled to rails 18 proximate to a wheel 12 with mounting mechanism 90(step 72). The position of cutting tool 24 relative to wheel 12 iscalibrated by first touching cutting tool 24 to wheel 12 at severalplaces and storing those positions in the computer controller. Accordingto one exemplary embodiment, as shown in FIGS. 9A and 9B, cutting tool24 is touched to wheel 12 at at least two places. A first point 60 is ontop of the flange 13 of wheel 12. A second point 62 is on the outsideedge or “rim” 17 of wheel 12. A third point 64 and a fourth point 66 areon the two contact points of the “tread” 15.

Wheel 12 is rotated so cutting tool 24 can profile the entirecircumference of wheel 12 (step 74). If 11 is a locomotive, wheel 12 maybe a driving wheel. However, powering the locomotive would cause all thedriving wheels on locomotive 11 to turn. To turn only the wheel beingprofiled by apparatus 20, an external power source is used. According toone exemplary embodiment, shown in FIG. 12 , wheel 12 is turned bypowering the traction motor 122 with a portable power source 120 such asa DC welder. If railcar 10 is an unpowered car, such as a box car, wheel12 is turned by a chain and sprocket drive mechanism 50, as shown inFIGS. 6 and 7 or a friction wheel drive mechanism 150, as shown in FIGS.13 and 14 .

With wheel 12 rotating, cutting tool 24 profiles wheel 12 in accordancewith a stored profile 82 in the computer controller 80 (step 76).Cutting tool 24 is moved by slide mechanism 35 along x-axis 40 andy-axis 42 with drive motors 32 and 36. According to one exemplaryembodiment, apparatus 20 may be used to machine wheel 12 to an AAR-IBregular flange profile (FIG. 9A) or an AAR-IB narrow flange profile(FIG. 9B). According to other exemplary embodiments, the computercontroller may provide other paths to apparatus 20 to machine wheel 12to another profile.

Once wheel 12 has been profiled by apparatus 20, railcar 10 orlocomotive 11 is lowered back onto rails 18 (step 78). Railcar 10 orlocomotive 11 may then be raised again to profile the other wheels or,if all wheels have been profiled, railcar 10 or locomotive 11 may bereturned to service.

Referring now to FIG. 11 , according to another exemplary embodiment,apparatus 20 used to profile wheel 12 is not a CNC lathe. Instead, atemplate 122 provides a path for cutting tool 24 of apparatus 20 whilean operator moves cutting tool 24 with a manual slide mechanism 130. Ahand wheel 132 is turned to move first slide 31 along drive shaft 110and a second hand wheel 136 is turned to move second slide 35 alongdrive shaft 112. Template 122 includes a profile 124 that describes adesired profile for wheel 12. Template 122 is positioned relative towheel 12 such that an arm 120 extending from apparatus 20 contactstemplate 122 at a position analogous to the position of cutting tool 24relative to wheel 12. The position of template 122 is calibrated byfirst touching cutting tool 24 to wheel 12 at several places andpositioning template 122 such that arm 120 contacts template 122 at thesame places. The calibration points may be similar to the calibrationpoints used to calibrate the CNC process described above or may bedifferent points.

For the purpose of this disclosure, the term “coupled” means the joiningof two members directly or indirectly to one another. Such joining maybe stationary in nature or moveable in nature. Such joining may beachieved with the two members or the two members and any additionalintermediate members being integrally formed as a single unitary bodywith one another or with the two members or the two members and anyadditional intermediate members being attached to one another. Suchjoining may be permanent in nature or may be removable or releasable innature.

It is important to note that the construction and arrangement of thewheel lathe as shown in the various exemplary embodiments isillustrative only. Although only a few embodiments of the presentinventions have been described in detail in this disclosure, thoseskilled in the art who review this disclosure will readily appreciatethat many modifications are possible (e.g., variations in sizes,dimensions, structures, shapes and proportions of the various elements,values of parameters, mounting arrangements, use of materials, colors,orientations, etc.) without materially departing from the novelteachings and advantages presented in the present application.Accordingly, all such modifications are intended to be included withinthe scope of the present disclosure. Other substitutions, modifications,changes and omissions may be made in the design, operating conditionsand arrangement of the various exemplary embodiments without departingfrom the scope of the present disclosure.

What is claimed is:
 1. A portable apparatus for profiling a first wheel,the apparatus comprising: a base; a cutter; a positioning systemconfigured to move the cutter relative to the first wheel along at leasttwo axes, the positioning system coupled to the base; and a computercontrol configured to control the positioning system, wherein thepositioning system is controlled so that the first wheel is profiled toa desired profile, wherein the first wheel is free to spin withoutcontact with the portable apparatus except at the cutter, wherein thecomputer control, the base, the positioning system and the cutter aredisposed below a center point of the first wheel and above a bottom of afirst rail associated with the first wheel, the base being attached tothe first rail.
 2. The apparatus of claim 1, further comprising aninterface for attaching the base to the first rail, the interfacecomprising a push rod in contact with a second rail.
 3. The apparatus ofclaim 2, wherein the cutter engages the first wheel.
 4. The apparatus ofclaim 1, wherein the two axes comprise a first axis parallel to an axleof the first wheel, and a second axis perpendicular to the axle.
 5. Theapparatus of claim 1, further comprising a motor system comprising oneor more gear reducers coupled to a second wheel on a same axle as thefirst wheel, the one or more gear reducers configured to reducerotational speed and increase torque to the second wheel.
 6. Theapparatus of claim 1 wherein the positioning system is configured tocalibrate a position of the cutter by moving the cutter to a pluralityof positions to touch a plurality of places of the first wheel, andwherein the computer control is configured to store the plurality ofpositions.
 7. The apparatus of claim 6 wherein the plurality ofpositions comprise at least one of a top of a flange of the first wheel,an outer edge of the first wheel, a first contact point and a secondcontact point on a tread of the first wheel.
 8. The apparatus of claim 1wherein the cutter is a high grade carbide lathe cutting tool.
 9. Theapparatus of claim 8, further comprising: a motor for driving a secondwheel on a same axle as the first wheel.
 10. The apparatus of claim 9,wherein the motor is configured to drive the second wheel via a bolt andsprocket or via a friction drive.
 11. A system configured to profile afirst wheel of a first pair of wheels mounted on an axle and disposed ona track with a first rail and a second rail in accordance with anelectronically stored profile, wherein the first wheel is raised whileallowing one or more second pairs of wheels to engage the track, thesystem comprising: a cutting tool disposed on the track and configuredto engage the first wheel; a positioning system configured to positionthe cutting tool; and a control configured to control the positioningsystem, wherein the positioning system is controlled so that the firstwheel is profiled to the electronically stored profile, wherein thecutting tool and the positioning system are disposed between a lineparallel to the first rail and through a center point of the firstwheel.
 12. The system of claim 11 wherein the control is a computercontroller and the profile is electronically stored in memory.
 13. Thesystem of claim 11 wherein the positioning system is coupled to amounting mechanism for engaging the track associated with a train. 14.The system of claim 12 wherein the cutting tool includes an insert. 15.The system of claim 12 further comprising a location bar for placementalong an edge of the track associated with a train.